Biofuels via hydrogenolysis and dehydrogenation-condensation

Abstract

A method comprising providing a carbohydrate feed; contacting at least a portion of the carbohydrate feed directly with hydrogen in the presence of a hydrogenolysis catalyst to produce a first reaction product comprising a stable hydroxyl intermediate; contacting at least a portion of the first reaction product comprising the stably hydroxyl intermediates with a dehydrogenation catalyst to form a second reaction product; and contacting at least a portion of the second reaction product with a condensation catalyst comprising a base functionality to form a fuel blend.

Description

[0001]The present application claims the benefit of pending U.S. Provisional Patent Application Ser. No. 61 / 333,916, filed May 12, 2010 the entire disclosure of which is hereby incorporated by reference.FIELD OF THE INVENTION[0002]The invention relates to the production of higher hydrocarbons suitable for use in transportation fuels and industrial chemicals from bio-based feedstocks.BACKGROUND OF THE INVENTION[0003]A significant amount of effort has been placed on developing new methods and systems for providing energy from resources other than fossil fuels. Bio-based feedstocks are a resource that show promise as a renewable alternative source of hydrocarbons for producing fuel and chemicals.[0004]Bio-based feedstocks including carbohydrates and “biomass” are materials derived from living or recently living biological materials. One type of biomass is cellulosic biomass. Cellulosic biomass is the most abundant source of carbohydrate in the world due to the lignocellulosic materials...

AI Technical Summary

Benefits of technology

[0022]An embodiment of the invention comprises providing a carbohydrate feed; contacting at least a portion of the carbohydrate feed directly with hydrogen in the presence of a hydrogenolysis catalyst to produce a first reaction product comprising stable hydroxyl intermediates; contacting at least a portion of the first reaction product comprising the stable hydroxyl intermediates with a dehydrogenation catalyst to form a second reaction product; and contacting at least a portion of the second reaction product with a condensation catalyst comprising a base functionality to form a fuel blend.

[0023]Carbohydrates are the most abundant, naturally occurring biomolecules. Plant materials store carbohydrates either as sugars, starches, celluloses, lignocelluloses, hemicelluloses, and any combination thereof. In one embodiment, the carbohydrates include monosaccharides, polysaccharides or mixtures of monosaccharides and polysaccharides. As used herein, the term “monosaccharides” refers to hydroxy aldehydes or hydroxy ketones that cannot be hydrolyzed to smaller units. Examples of monosaccharides include, but are not limited to, dextrose, glucose, fructose and galactose. As used herein, the term “polysaccharides” refers to saccharides comprising two or more monosaccharide units. Examples of polysaccharides include, but are not limited to, sucrose, maltose, cellobiose, cellulose and lactose. Carbohydrates are produced during photosynthesis, a process in which carbon dioxide is converted into organic compounds as a way to store energy. The carbohydrates are highly reactive compounds that can be easily oxidized to generate energy, carbon dioxide, and water. The presence of oxygen in the molecular structure of carbohydrates contributes to the reactivity of the compound. Water soluble carbohydrates react with hydrogen over catalyst(s) to generate stable hydroxyl intermediates comprising polyols and sugar alcohols, either by hydrogenation, hydrogenolysis or both.

[0024]In the embodiment shown in FIG. 1, the carbohydrates are optionally reacted in a hydrogenation reaction and then a hydrogenolysis reaction to form suitable stable hydroxyl intermediates that comprise alcohols and polyols for the condensation reaction 110. In an embodiment of the invention, the hydrogenation reaction is optional and the hydrogenolysis reaction alone is suitable to form the desired stable hydroxyl intermediates. In another embodiment of the invention, the carbohydrates are passed through the hydrogenolysis reaction prior to being passed through the hydrogenation reaction (thus hydrogenolysis reaction 106 and hydrogenation reaction 104 are reversed from the order shown in FIG. 1). In an embodiment of the invention, the hydrogenation and hydrogenolysis reactions occur in the same vessel to generate stable hydroxyl intermediates to be fed into a processing reaction. In an embodiment, a separation step (e.g., water removal) could be conducted prior to the hydrogenolysis reaction.

[0025]The carbohydrates may originate from any suitable source. In an embodiment, the carbohydrates fed to the process may be derived from an organic source (e.g., sugars and starches from corn or sugarcane). In another embodiment, the carbohydrates are derived from bio-based feedstocks. Bio-based feedstocks can include biomass. As used herein, the term “biomass” means organic materials produced by plants (e.g., leaves, roots, seeds and stalks), and microbial and animal metabolic wastes. Common sources of biomass include: agricultural wastes (e.g., corn stalks, straw, seed hulls, sugarcane leavings, bagasse, nutshells, and manure from cattle, poultry, and hogs); wood materials (e.g., wood or bark, sawdust, timber slash, and mill scrap); municipal waste, (e.g

Problems solved by technology

For example, the processes used are costly and complex making it difficult to compete with the use of traditional resources, such as fossil fuels.

The conversion of carbohydrates to hydrocarbons in this system results in increased loss of desirable hydrocarbon products due to the formation of unwanted byproducts, such as coke, carbon dioxide, and carbon monoxide.

Thus, another challenge for promoting and sustai

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